Pants type diaper and method for producing same

ABSTRACT

A pants-type diaper, is provided which is equipped with leg-hole elastics which effectively encircle the leg-holes without traversing the crotch region. Also provided are methods for producing such diapers. Typical products of this type are provided with an outer laminate, formed of an inner liner material and an outer backsheet material between which the leg-hole elastics are disposed. The invention provides for the removal of a strip of inner liner material carrying undesirable crotch-region elastic strands prior to lamination or combining of the remaining inner liner with a complementary outer layer backsheet.

RELATED APPLICATION

[0001] This application is a continuation of co-pending application U.S.Ser. No. 10/085,908, filed Feb. 28, 2002, which is a divisional of U.S.Ser. No. 09/537,157, filed Mar. 29, 2000, and which is now U.S. Pat. No.6,482,278.

BACKGROUND OF THE INVENTION

[0002] The invention relates to disposable garments, and moreparticularly, a pants-type diaper, which is equipped with elasticsstrips effectively encircling the leg-holes without traversing thecrotch region and to a method for producing such diapers.

[0003] Disposable diapers of the children's training pant type, or ofthe adult incontinence type, are typically equipped with elasticstrands, which encircle the leg-holes. These strands of elastic aretypically captured with adhesive between two layers of non-wovenmaterials. Various methods are used to position these elastic strands sothat they produce the desired encircling effect.

[0004] In one method of manufacture, the diapers are produced in anorientation whereby product flow is in the form of a single continuousweb and the direction of travel is at a right angle with respect to whatwould be described as the crotch line of the diaper, i.e., the normaldirection of product flow is parallel to the waist as opposed toparallel to the crotch.

[0005] One method of creating the desired effect of encircling the legholes of the pant with elastics is to interleave two swaths of elasticstrands, each curving across the face of the traveling web, encirclingabout one half of the leg-hole areas and crossing the path of the other.As a pair, they create a boundary around each leg-hole cutout, whichresembles a circle or ellipse. In practice, however, the lateralexcursions of the elastic lay-down device are speed-limited. As thetraveling web is moving at some speed in one direction, and as theelastic lay-down device has speed and acceleration limits in thecross-direction, there is a limit to the steepness of the oblique anglewhich it is possible to form between the two. The result of thislimitation is usually seen in the form of apparent incompleteness in theformation of the leg-hole-encircling pattern, particularly at the crotchline, where the two swaths cross each other.

[0006] From the point on the web at which one leg-hole pattern has beencompleted to the point at which the next can be begun, the elasticlaydown device must reposition itself to a favorable starting point.This period of repositioning occurs as the crotch region passes thelaydown device. As a result, the elastic strands must also cross thisregion of the product, at which they may or may not be attached by meansof adhesives to the carrier webs. Various means are used to control orlimit the positional relationships of the elastic strands in thisregion. The two sets of strands may cross over each other, creating an“X” pattern, or, they may loop back over to their respective sides,creating an “O” at the center of the crotch region. Alternatively, theymay be mechanically stopped and prevented from crossing each other,creating two sets of generally parallel lines at the crotch The lay-downpattern used at the crotch will determine the final appearance of theproduct in this area.

[0007] The shirring effect created by elastic strands when laminatedwith any flexible fabric is well known. However, to have this shirringeffect applied to the crotch of a pant-type garment can be undesirable.The elastics create a contractile force, which tends to distort thegarment at this location, thereby reducing the garment's aestheticappeal, effectiveness and comfort. Thus various methods of reducing oreliminating the effects of the elastic tension normally occurring at thecrotch have been attempted. These methods include the elimination of theadhesive bond between the strands and the liner materials described inU.S. Pat. No. 5,745,922 as “unsecured space” as well as various methodsof cutting the strands to eliminate their effects.

[0008] While the presence of the leg-hole elastic strands at the crotchregion is claimed by some to be of benefit in biasing the diaper's innercuffs against the user's legs see U.S. Pat. No. 5,188,627; Igaue, et al,it is believed by the present applicants that the disadvantages,described above, outweigh any advantages.

[0009] As mentioned, one method of eliminating the undesired effects ofthe elastic strands which cross the crotch region is to sever them. Thismethod is described in U.S. Pat. No. 5,660,657. Unfortunately, suchsevering usually requires the introduction of a transversely extendingcut, which can result in a loss of web tension in the severed part ofthe carrier web. This also creates an undesirable opening in the diaperbacksheet. A proposed solution for this problem is taught in U.S. Pat.No. 5,707,470, wherein an ultrasonic device is used to sever the elasticmembers, while the carrier webs which encapsulate the elastics are leftintact. See, also, U.S. Pat. No. 5,643,396. Another problem associatedwith such severing lies in the tendency of the unsecured severed ends ofelastic to retract to some point beyond the limits of any adhesivepattern. Thus, the elastic strands are not controlled or anchored nearthe ends of the adhesion pattern and may snap back to further into theadhesive pattern. This results in an incomplete elastic pattern and poorproduct characteristics.

[0010] One method of compensating for the incompleteness of theencircling pattern entails insertion of an additional set of elasticstrips, running parallel to the crotch line and transverse to the webpath. See U.S. Pat. Nos. 5,634,917 and 5,660,657. Typical products ofthis type are provided with an outer laminate, which is formed of aninner liner material and an outer backsheet material, between which theleg-hole elastics are disposed.

SUMMARY OF THE INVENTION

[0011] It is a principal object of this invention to provide an improvedmethod of producing pants type diapers and to provide the resultantimproved diapers. A pants-type diaper, is provided which is equippedwith leg-hole elastics which effectively encircle the leg-holes withouttraversing the crotch region.

[0012] In accordance with one aspect of the invention, elastic strandsare eliminated from the crotch region of a pants type diaper. Inaccordance with a related aspect, the invention provides a methodwherein undesirable elastic material is encapsulated and then aninterior longitudinal zone of material which contains the undesirableelastic is cut away and removed. The invention provides for the removalof a strip of inner liner material carrying the undesirablecrotch-region strands before the remaining inner liner is combined orlaminated with its complementary outer backsheet layer.

[0013] In accordance with a further related aspect, the remaining webs,which contain elastic strands, are subsequently laminated with a coversheet. In a preferred embodiment of the invention, the remaining websmay be rejoined before lamination, thereby reducing the segment of legopening perimeter which is removed.

[0014] In one embodiment, the leg-hole elastic swaths are laid down onan inner non-woven carrier web, following appropriate curving patterns.The resultant composite web is then longitudinally slit into twonarrower webs. The inside edge of each narrower web is then foldedlongitudinally to cover that part of the elastic pattern which is to beremoved. This operation serves to cover the exposed adhesive and toentrap the elastics in this area. The entrapped elastics and thematerial within which they are enclosed are then removed by againslitting the edge of the webs and scrapping the waste edges. Theremaining webs, with their semicircular elastic patterns intact may thenbe subsequently brought back to positions of contiguity by guidingmeans. This relocation brings the two semi-circles together to form morenearly perfect elastic circles or ellipses. The two narrower webs arethen laminated with an outer carrier web, which entraps the remainingelastic swaths, creating a final laminated outer backsheet for thepant-type diaper. Subsequent processes insert an absorbent chassis orpad, cut out the leg-hole, fold the web longitudinally, and seal and cutthe web into individual pants type diapers.

[0015] A second embodiment of the invention involves a similar process,but differs, in that instead of folding the slit edge of the web over tocover and entrap the elastics which are to be removed, separate stripsof web material are introduced for this purpose. Such web strips may beobtained by slitting them from either the outer or inner edges of twonarrow webs.

[0016] A third embodiment, a variant of the second embodiment, coversand entraps the elastics with a single, wider strip of material. Suchweb may be an edge previously cut and removed from the inner linermaterial or may be separate material provided for this purpose.

[0017] A fourth embodiment may be similar to one of the first, second orthird embodiments, but differs in that the two narrow webs are notbrought together prior to lamination. Instead, the gaps or missingsegments between two semi-circles around the leg openings are replacedby elastics provided in the edges of an absorbent chassis or pad, whichoverlays the crotch area.

[0018] In a yet further embodiment of the invention the intermediatenarrow strip of material is eliminated. A single web, or if desired, apair of traveling webs are provided onto each of which an adhesivepattern is applied. The elastic strips are laid down on the adhesive ina serpentine pattern. The strips may be firmly secured to the adhesiveby pressing them into the adhesive, for example, by using a pressureroll. A chilled slitting knife may be used in order to minimize adhesivebuild-up or contamination on the knives. Also, the adhesive can beapplied in a pattern which leaves a gap in a strip along which slittingtakes place, order to facilitate clean cutting of the composite web.After slitting and removal of the trim, a back sheet is applied whichresults in the elastic strips being sandwiched between the slit webs andthe backsheet.

[0019] Briefly, a preferred method of the invention includes the stepsof providing a web, defining on the web a portion of a pants type diaperincluding locations for leg openings and a crotch area there between.Then, a layer of adhesive is applied around the leg openings and acrossthe crotch area.

[0020] An elastic ribbon is laid down on the adhesive in a semicircularpattern around the leg openings and across the crotch area. Subsequentlya narrow web is laid down over the elastic and the adhesive in thecrotch area. Then the web is longitudinally slit to sever at least aportion of the narrow web and the unwanted elastic in the crotch area.The removed materials are scrapped, resulting in a pants-type diaperwithout elastic in the crotch region.

[0021] A cover sheet is laminated over the remaining web, and, allmaterial is removed from the leg openings. An absorbent pad ispreferably attached over the crotch area. The absorbent pad mayoptionally be provided with elastic strips adjacent opposite lateraledges which serve to complete the encirclement of the leg openings byelastic material.

[0022] The invention, thus, produces a disposable garment including afront body portion, a back body portion and an intermediate crotchportion with spaced left and right leg openings on opposite sides ofsaid crotch portion. The edges of the front and back body portions arejoined to form a waist portion, the leg openings each having an upperperiphery adjacent to the waist portion and a lower periphery adjacentto the crotch portion. The garment, further, includes a back sheet whichforms an outer surface thereof, a top sheet and an absorbent padpositioned in the crotch area. In accordance with the invention, thereare front left and right elastic strands which extend, respectively,around a quadrant of each of the leg openings from forward ends whichterminate at a forward part of the crotch portion and around the upperperiphery of each of the left and right leg openings to the side seam.Similarly, rear left and right elastic strands extend, respectively,around another quadrant of each of the leg openings from rearward endswhich terminate at a rearward part of the crotch portion and extendaround the upper periphery of each of the left and right leg openings tothe side seam. The strands are adhered to the top sheet, and to firstand second narrow webs sandwiched between the top sheet and the backsheet. The first narrow web is adhered to the forward ends of each ofthe left and right elastic strands and the second narrow web is adheredto the rearward ends of each of the left and right elastic strands.

[0023] In its most basic form, the invention provides a method offorming pants type diapers which includes the steps of (a) providing atraveling fabric web upon which is defined a portion of a pants typediaper including locations thereon for leg openings and a crotch areatherebetween, (b) applying an adhesive pattern on the web around the legopenings, (c) laying down strips of elastic material on the adhesive inan undulating pattern around the leg opening locations on the travelingweb and across the crotch area, (d) forming a pair of parallellongitudinal slits along the center of the traveling web to sever thecentral portion of the web thereby severing the elastic in the crotcharea, (e) removing the severed portion of the traveling web and theelastic, laminating a cover sheet over the severed halves of thetraveling web, (f) cutting and removing all material from the legopenings, (g) severing the web into individual diaper blanks, (h)folding the blanks in half across the crotch area, and, (i) sealing theedges of the blank together on each side thereof to form a pants-typediaper.

[0024] Further objects and advantages of the invention will be apparentfrom the following detailed description, the attached claims and thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025]FIGS. 1a-1 c, collectively, are a perspective view showing apreferred embodiment of the invention in somewhat diagrammatic fashion;

[0026]FIG. 2 is a diagrammatic view of the equipment and process shownin FIGS. 1a-1 c;

[0027]FIGS. 3a-3 b are, collectively, a perspective view showing insomewhat diagrammatic fashion an alternative embodiment of theinvention;

[0028]FIG. 4 is a diagrammatic view further illustrating the process andequipment shown in FIGS. 3a-3 b;

[0029]FIGS. 5a-5 g are a series of fragmentary plan views showingsections of the web as it passes through the process and apparatus ofFIGS. 1a-1 c and 2;

[0030]FIG. 5h is a fragmentary plan view showing a step subsequent tothat depicted in FIG. 5g but viewed from the opposite side of the web;

[0031]FIG. 6a is a fragmentary plan view showing a web section at apoint where it leaves combining role number 124 in FIG. 3a;

[0032]FIG. 6b is a fragmentary plan view viewed from the oppositedirection shown in FIG. 6a and showing a section of the web after itleaves roller 46 depicted in FIG. 3b;

[0033]FIGS. 7a-7 g are fragmentary top plan views showing yet anotherembodiment of the invention;

[0034]FIG. 7h is a fragmentary top plan view taken from the opposite ofthe web shown in FIGS. 7a-7 g at a subsequent point in the process;

[0035]FIG. 8 is a top plan view showing an unfolded diaper blankproduced in accordance with the invention with the leg openings removed;

[0036]FIG. 9a is a perspective view of the diaper blank of FIG. 8;

[0037]FIG. 9b is a perspective view showing the diaper of FIGS. 8 and 9aafter final assembly thereof;

[0038]FIG. 10 is a fragmentary enlarged perspective view showing the legopening and elastics of the diaper of FIG. 9b;

[0039]FIG. 11 is a fragmentary perspective view showing anotherembodiment of the invention in somewhat diagrammatic fashion;

[0040]FIGS. 12a-12 c are a series of fragmentary plan views showingsections of webs as passing through the process and apparatus of FIG.11; and,

[0041]FIGS. 13a-13 c are another series of fragmentary plan viewsshowing sections of webs as passing through the apparatus of FIG. 11 inaccordance with a modified process.

DETAILED DESCRIPTION OF THE INVENTION

[0042] Referring first to FIGS. 1a, 1 b and 1 c, one of the preferredembodiments of the process of this invention and related apparatus areillustrated. The process utilizes two main carrier webs; a non-woven web11 which forms an inner liner web, while web 12 forms an outwardlyfacing layer in the finished diaper. In this embodiment, non-woven web11 is slit, at slitter station 15, by rotary knives 14 along threelines. One of these, line 16, is on approximately the centerline of web11 and two additional lines 17 and 18 are parallel to and spaced a shortdistance from centerline 16. (See FIG. 5a.) The effect is twofold,first, to separate web 11 into two halves, as also seen in FIG. 5b. Onehalf, 19, will become the inside of the front of the diaper 50 and thesecond half, 20, will become the inside of the back of that garment.Second, two separate, relatively narrow strips 22 and 24 are formedwhich are subsequently used to cover and entrap portions of the leg-holeelastics 25 and 26. Strips 22 and 24 are separated physically by anangularly disposed spreader roll 23 and aligned laterally with theirdownstream target positions on the inner edges of webs 19 and 20.

[0043] As shown in FIG. 5c, adhesive patterns 21 and 27 are applied tothe web halves 19 and 20 in the target areas for the leg hole elastics25 and 26. A spray gun assembly 29 of a type known in the art ispreferably used to apply adhesive patterns 21 and 27. Two sets ofleg-hole elastic strands 25 and 26 are introduced through laydown guides28 and 30, which reciprocate from side to side past each other. Strands25 and 26 are glued to the web sections 19 and 20, their laydownpatterns following a serpentine path. Given the absence of adhesive inthe area separating web 19 from web 20, for some portion of eachsuccessive diaper product, the strands 25 and 26 each track parallel tothe inner slit edges of the web sections 19 and 20. Laydown guides 28and 30, thus, apply the strands 25 and 26 which form leg-hole elasticsas the web sections 19 and 20 are carried along the face of a drum orroll 32. Those parts of the elastic patterns which are near the innerslit edges of webs 19 and 20 are then covered by the introduction of anadhesive lamination thereover of the strips 22 and 24 of non-woven webalso against the drum 32.

[0044] The side-to-side excursions of the leg-hole elastic laydownguides 28 and 30 result in arcuate segments of elastic strands extendingon each side of the web centerline as seen in FIGS. 5d and 5 e. Afterthe non-woven strips 22 and 24 have been applied to cover and entrapthose parts of the elastics 25 and 26 which run nearest to and parallelto the inner edges of the webs 19 and 20, a second pair of slitterknives 34 (FIG. 2) are used to trim away a portion of the narrownon-woven strips 22, 24, along with that part of the inner liner webs19, 20 to which they are laminated. This also removes those portions ofthe elastic strands 25, 26 which are contained within the laminations.The resultant trimmed scrap strips 36 are removed from the process fordisposal elsewhere.

[0045] The effect of the last-described step is to totally remove thecut away portions of the elastic, eliminating its corresponding unwantedgathering effect from the crotch region of the garments 50. Theremaining portions of the curved elastic strands create a gatheringeffect around the leg openings of the finished garments 50.

[0046] Subsequent to the combining and trimming of the inner webs 19, 20and the cover strips 22, 24, the combining drum 32 carries the webs to apoint of approximate tangency with a second combining drum 38, where theweb sections 19, 20, with their respective curved elastic patterns 21and 27 exposed, are transferred to and laminated adhesively against theinside face of outer liner web 12. This process entraps the curvedelastic patterns 25, 26 between the inner and outer chassis webs 19, 20and web 12 thereby forming a composite web 39.

[0047] A succession of absorbent pads 40 are picked up at a supplystation 41 by vacuum heads 44 of a pad supplying/turning device 42. Theabsorbent pads 40 are comprised of various absorbent materials containedwithin a non-woven cover stock which are well known in the art. The padsare rotated 90° and applied, successively, to the crotch areas of thecomposite web 39 by a transfer roll 46 where they are attachedadhesively to the inside of the web 39 which forms the garment chassis.FIG. 5h shows a pad 40 attached to the composite web 39. It should benoted that in FIG. 5h the web 39 is being viewed from the opposite sidefrom that which is shown in FIGS. 5a through 5 g.

[0048] Leg hole materials 48, if not previously removed, are cut at acutting station 47, thereby removing the material 48 contained within anapproximate perimeter defined by the curved pattern of the elastics 25,26. The running composite chassis web 39 is folded, before or aftercutting out of the leg holes, longitudinally along its centerline,thereby aligning its front waist edge 51 with its back waist edge 52.The regions 53 which are to become the side seams 54 of the garments 50are then welded by a sealing device 49 either ultrasonically or by heat.Note that the leg-holes are preferably cut out before this point,leaving only a narrow zone for welding. The weld pattern is preferablywide enough to extend into both the left side seam of one garment andthe right side seam of the adjacent garment. The garments 50 are thenseparated by passing through a cut-off knife assembly 55, which seversthe web along the transverse axis of the side seam weld 53.

[0049] Referring to FIG. 3, there is shown an alternate embodiment ofthe invention which provides a process that results in bringing of thefront and back leg hole elastics into closer proximity with each other.In the embodiment shown in FIGS. 3a and 3 b, this is accomplished bybeginning with a web of material 111 and slitting the same, for example,by means of a rotary knife 114 into two halves, 119 and 120. It will beappreciated that instead of cutting the web 111 into halves that theprocess could also be practiced by providing the narrower webs 119 and120 from two separate sources of material. As shown, the two webs 119and 120 are brought into the process utilizing two separate combiningdrums, 121 and 122, each of which lays down its respective web 119 and120 onto a larger rotating drum 124. In the illustrated embodiment anarrow strip 126 is removed by means of a rotary knife 125 from web 119.Similarly a rotary knife 128 removes a strip 129 from web 120. As shownin FIG. 3a, elastic strands 130 are applied in an oscillating patternonto web 119 at combining drum 121 and the inwardly facing edges thereofare covered by the narrow web 126. Similarly an elastic 132 is appliedto web 120 immediately prior to covering of the inwardly facing edgethereof by means of narrow web 129. Adhesive patterns are applied byapplicators 134 and 136, respectively, to form spray patterns 140 and138 which are shown in FIGS. 6a and 6 b. After the elastic 130 has beenlaid upon web 119 on combining drum 121, the inwardly facing edgethereof is cut by means of a rotary cutter 142, thereby removing a stripof scrap material 144 which includes the inner edges of web 119 andnarrow strip 126 together with that portion of elastic 130 which issandwiched therebetween. The identical process takes place on combiningdrum 122 with respect to web half 120 where, after lamination of elastic132 between the inner edge of web 120 and narrow strip 129, a rotaryknife 146 removes the severed portion of the webs and elastic 148. Theresultant laminated webs 119 and 120 are then applied to a backsheet web150 on combining drum 124. This results in a combined web 152, alsoillustrated in FIG. 6a.

[0050] Then, as in the case of the earlier described embodiment, a padturning and supplying assembly 42 utilizing vacuum heads 40 supplies aseries of absorbent pads 153 to a transfer roll 46 which applies eachpad successively in each crotch area on the combined web 152. As bestseen in FIG. 6b, the absorbent pads 153 may be supported on a sheet ofabsorbent web material 154 which is bonded to the composite web 152 bymeans of ultrasonic welding, heat, or, if desired, by means ofadhesives. As best seen in FIG. 6a the bringing of the webs 119 and 120into close proximity to each other makes it possible for the elastics130 and 132 to effectively encircle the leg areas with only aninsignificant gap between them. This reduces or eliminates the need forintroducing elastics along the lateral edges of the pads 153.

[0051] The embodiment of FIGS. 3a and 3 b is shown in diagrammatic formin FIG. 4. FIG. 4 also illustrates the steps of folding the compositeweb in half at a folding station 156, cutting out the leg hole material159 and a cutting station 158. Then, side seams 161 are formed at asealing station 160. The side seams 161 are severed along theirapproximate center line at another cutting station 162. This results inthe finished diaper garment 164 which have side seams 161 on each sideof the garment.

[0052] Referring to FIGS. 8-10, there is seen, in FIGS. 8 and 9a, ablank for a diaper garment 50 which may be produced by the apparatus andmethod shown in FIGS. 1-1 c or, alternatively, by that shown in FIGS.7a-7 h. In this embodiment the leg openings have been cut out leavingthe strands 25 and 26 partially encircling the leg openings. A pad 40supported on a web 60, which may also be formed of non-woven absorbentmaterial, has been applied to the crotch area. A separate strand ofelastic material 62 and 64 positioned on opposite sides of the pad 40provides a means to complete the approximate encirclement of the legopenings by means of elastic material which, as in the earlier describedembodiment, is somewhat discontinuous. Thus, the ends of elastic strands25 and 26 which are inwardly terminating in the crotch area are securedby the narrow webs 22 and 24 as seen in FIGS. 9a and 9 b, as well as inFIG. 10. The elastic strands 62 and 64 are thus spaced away from theends of elastics 25 and 26. This arrangement provides for a comfortablefit around the legs of a wearer but without any bunching tendency in thecrotch area which might cause discomfort.

[0053] Also, as seen in FIGS. 9-10 waist elastics 66 are provided onopposite sides of the garment blank which, after folding together andformation of the side seams 54, entirely encircle the waist area of thefinished garment 50. Note, also, in FIGS. 9b and 10 that the ends of theelastics 25 and 26 which extend furthest away from the crotch area alsobecome secured by means of the side seams 54.

[0054] Referring next to FIGS. 7a-7 h, there is illustrated a sequenceof steps illustrating yet another embodiment of the invention. Inaccordance with the embodiment of 7 a-7 h, a web 211, as depicted inFIG. 7a, is slit into two halves 219 and 220 as it travels through theprocess. Then, adhesive patterns 221 and 227 are applied, as shown inFIG. 7c, to the respective web halves 219 and 220. Elastic strips 225and 226 are then applied in an undulating pattern, as shown in FIG. 7d.Then, the inner edges of the webs 219 and 220 are folded over onthemselves thereby covering and securing the portions of elastic strips225 and 226 which are nearest the cut line 218 between webs 219 and 220.As also seen, the portions of elastic strands 225 and 226 which traversethe crotch region of the diaper being manufactured are captured alongthe fold line between folded over strip 222 and the remainder of web 219and similarly along the fold line between the folded over portion 224and the remainder of web 220.

[0055] Referring to FIG. 7f, the two web halves 219 and 220 are seenafter severance therefrom of the inner edges or folds of the folded overflap portions 222 and 224. Thus, it will be appreciated that the ends ofelastic strands 225 and 226 nearest the crotch region of the diaper areanchored in place by the remaining width of the strips 222 and 224 andthe webs 219 and 220, respectively.

[0056] In FIG. 7g a cover sheet 212 has been laminated over the webhalves 219 and 220. The adhesive areas 221 and 227 which flow into thewebs 219 and 220 are not shown in this view, since they are no longerdiscrete entities. The elastic strands 225 and 226 have been at thispoint sandwiched between the layers 212 and 219 or 220, respectivelywith the ends thereof firmly anchored by the narrow strips 222 and 224which are also sandwiched between the covering web 212 and the originalweb halves 219 and 220.

[0057] Referring to FIG. 7h, the assembled diaper forming materials ofFIG. 7g are shown from the opposite side of the web and with anabsorbent pad 240 secured thereto. As in the earlier embodiments, pad240 is attached to a supporting web 260. Also, in this case elasticstrands 262 and 264 are attached to the carrier web 260 so that the gapsbetween the ends of each of the elastics 225 and 226 which lie closestto the diaper crotch area are provided with an elastic material. Note,again, that the strands 262 and 264 are displaced slightly from the endsof the strands 225 and 226 which are anchored by the narrow strips 222and 224. It will, thus, be appreciated that after the removal of the legopening materials from the combined webs of FIG. 7h, a blank is providedwhich is virtually identical to that shown in FIGS. 8 and 9a.Accordingly, the resultant diaper is also virtually identical to thatillustrated in FIGS. 9b and 10.

[0058] Referring to FIG. 11, there is seen a modified process of thisinvention wherein the narrow covering strips 22 and 24, shown inconnection with the earlier described embodiments, are not used.Instead, diapers and diaper blanks are produced wherein elastic strands25 and 26 become sandwiched between a fabric web 311 and a back sheet12. In FIG. 11 the apparatus and components having the same numbers usedin connection the earlier described embodiments refer to the samecomponents.

[0059] As seen in FIG. 11, a non-woven web 311 is cut along its centerline, longitudinally, by means of a rotary knife 14 along a central cutline 318, thus forming two narrower web halves 319 and 320. A sequenceof the processing steps relating to the web halves 319 and 320 areillustrated in part in FIGS. 12a-12 c, steps which are omitted beingsimilar to those shown in connection with the earlier-describedembodiments. As in the case of the earlier embodiments, adhesivepatterns 320 and 321 are applied to the web halves 319 and 320 by meansof an adhesive applicator 29. Then, elastic strands 25 and 26 are laiddown by means of reciprocating feeding devices 328 and 330, resulting ina pattern such as illustrated in FIG. 12b. Note that intended trim lines340 and 342 are shown for illustrative purposes in FIGS. 12a and 12 b bymeans of phantom lines. Note also from these figures that the adhesivepatterns 321 and 327 are omitted from strips over the cut lines 340 and342. This procedure facilitates slitting of the webs 319 and 320 alongthe trim lines 340 and 342, respectively. The slitting knives, thus,serve to cut the webs along these lines 340 and 342 without undoaccumulation of adhesive on the knives.

[0060] The web halves 319 and 320 are shown subsequent to slitting andremoval of the elastic strips 25 and 26 from the crotch area in FIG.12c. It will then be appreciated that when an outside covering web 12 isapplied over the parallel traveling web halves 319 and 320 that theelastic strands 325 and 326 will be sandwiched between the webs 12 and319 or 320 and thus firmly held in place. Only a small, inconsequentialend of each of the strands 25 or 26 adjacent to the slit lines 340 and342 is left unanchored by the adhesives.

[0061] Referring to FIGS. 13a-13 c in conjunction with FIG. 11, afurther embodiment of the invention will be described. In this variationthe web 311 is not slit by a rotary knife prior to application of theadhesive patterns thereto. Thus, the rotary knife 14 of FIG. 11 can beomitted. As seen in FIG. 13a, the web 311 is intact when the adhesivepatterns 421 and 427 are applied. In other respects, these adhesivepatterns are similar to those illustrated in FIGS. 12a-12 c. As in thatcase, the trim lines 440 and 442 are again shown by means of phantomlines. Also, again, the adhesive patterns 421 and 427 can be configuredso that adhesive is omitted from strips along the intended trim lines.After application of elastic strands 25 and 26 over the adhesivepatterns 421 and 427, the web 311 is slit along the two parallel lines440 and 442 resulting in two web segments 419 and 420, as seen in FIG.13c. As noted by a comparison of FIGS. 12c and 13 c, both of theseprocedures result in virtually identical diaper blanks. Subsequently,the leg hole areas are removed as in the case of the earlier embodimentsand waistband elastics can be applied at a convenient point in theprocess. Then, the blanks are formed into finished diapers, just as inthe case of the earlier described embodiments.

[0062] While various preferred embodiments of the invention have beenshown for purposes of illustration, it will be apparent to those skilledin the art that various additional modifications can be made fallingwithin the scope of the invention as defined by the appended claims.

We claim:
 1. A protective underwear arranged to be worn by a personhaving legs to trap and collect loose or liquid waste products of theperson, said underwear comprising a pants-shaped chassis having a frontwaist portion, a belly portion, a rear waist portion, a rear backportion, a crotch portion, and a pair of leg openings disposed onopposite sides of said chassis, with said crotch portion being locatedbetween said leg openings and having a front section and a rear section,said front waist portion and said rear waist portion being joinedtogether at the sides of said chassis, said belly portion and said rearback portion being joined together at the sides of said chassis, saidunderwear additionally comprising an insert having an insert sheet and aliquid absorbent core disposed between said insert sheet and saidchassis, each of said leg openings having a first arcuate section, asecond arcuate section, and an intermediate section, said first arcuatesection having an inner end located adjacent said core, said secondarcuate section having an inner end located adjacent said core, saidintermediate section being located adjacent said core between said innerends of said first and second arcuate sections, said front waist portionof said chassis including plural transversely oriented elastic threadsextending parallel to one another, said plural transversely orientedelastic threads encompassing a substantial portion of said chassis fromsaid waist portion into said belly portion to a point adjacent saidcrotch portion, said underwear additionally comprising at least twogenerally linear longitudinally oriented elastic threads, withrespective ones of said longitudinally oriented elastic threadsextending on opposite sides of said core outside margins of said coreand between said leg openings, said longitudinally oriented elasticthreads intersecting at least one of said transversely oriented elasticthreads of said belly portion and intersecting at least one of saidtransversely oriented elastic threads of said rear back portion to forman enclosed, rectangular gasketed compartment for said liquid absorbentcore closely conforming to the perimeter of said core to prevent theegress of liquid therefrom, said first arcuate section of each of saidleg openings being elasticized by at least one arcuate elastic thread,said second arcuate section of each of said leg openings beingelasticized by at least one arcuate elastic thread, said at least oneelastic thread of said first arcuate section terminating at an innerend, said at least one elastic thread of said second arcuate sectionterminating at an inner end, said inner ends being spaced from eachother by a gap, said gap being located at said intermediate section, andwherein a portion of one of said longitudinally oriented elastic threadsis located very close to said gap in said intermediate section of one ofsaid leg openings, and a portion of the other of said longitudinallyoriented elastic threads is located very close to said gap in saidintermediate section of the other of said leg openings, whereupon saidlongitudinally oriented elastic threads cooperate with said arcuateelastic threads to elasticized said leg openings to enable said legopenings to closely conform about the legs of the person.
 2. Theprotective underwear of claim 1 wherein said compartment has an area,wherein said insert sheet and said chassis are liquid permeable, andwherein said underwear additionally comprises a liquid impermeable layerdisposed between said core and said chassis and encompassing said areaof said compartment.
 3. The protective underwear of claim 1 wherein saidunderwear additionally comprises a fluid acquisition layer locatedbetween said insert sheet and said liquid absorbent core within saidcompartment.
 4. The protective underwear of claim 1 wherein saidtransversely oriented elastic threads comprise two first groups and twosecond groups, a first one of said two first groups being located insaid front waist portion and a second one of said first two groups beinglocated in said rear waist portion, a first one of said two secondgroups being located in said belly portion and a second one of said twosecond groups being located in said rear back portion, and wherein saidtransversely oriented threads of said first groups are spaced closer toone another than said transversely oriented threads of said secondgroups.
 5. The protective underwear of claim 1 wherein said underwearincludes a front section comprising said front waist portion and saidbelly portion and a rear section comprising said rear waist portion andsaid rear back portion and wherein portions of said transverselyextending threads that are located in either said front section or saidrear section of a distinctive color are compared to said chassis to bereadily visible by the person.
 6. The protective underwear of claim 1wherein said compartment has a periphery and said insert sheet and saidchassis are bonded about said periphery of said compartment.
 7. Theprotective underwear of claim 1 wherein said core is of a generallyrectangular shape.
 8. The protective underwear of claim 1 wherein saidchassis comprises a backsheet and two inner sheets adhesively secured tosaid backsheet, said inner sheets being of non-woven material.
 9. Theprotective underwear of claim 1 wherein said transversely orientedelastic threads and said longitudinally oriented linear elastic threadssre of the same material.
 10. The protective underwear of claim 9wherein said arcuate elastic threads are of a different material thansaid transversely oriented elastic threads.
 11. The protective underwearof claim 1 wherein said chassis material is a polylaminate.
 12. Theprotective underwear of claim 11 wherein said polylaminate is polyfilmlaminated to a non-woven material.
 13. The protective underwear of claim1 wherein said insert sheet comprises a non-woven material.
 14. Theprotective underwear of claim 13 wherein said non-woven material isspunbond polypropylene.
 15. The protective underwear of claim 13 wheresaid non-woven material is zone-coated spunbond polypropylene, having alongitudinal central area that is hydrophilic and two longitudinal sideareas that are hydrophobic.
 16. The protective underwear of claim 1wherein said core is formed of a highly moisture absorbent material. 17.The protective underwear of claim 16 wherein said core is formed of pulpand a superabsorbent particulate.
 18. The protective underwear of claim16 wherein said core is formed of an airlaid composite, containing pulp,superabsorbent particulates and/or fibers, and at least one binder. 19.The protective underwear of claim 18 wherein said at least one binder isselected from the group consisting of chemical and thermal binders. 20.The protective underwear of claim 1 wherein said chassis comprises anon-woven material.
 21. The protective underwear of claim 20 whereinsaid non-woven material is a spunbond polypropylene material.
 22. Theprotective underwear of claim 20 wherein said non-woven material isspunbond/meltblown/spunbond polypropylene.
 23. The protective underwearof claim 22 wherein said insert sheet is an apertured three dimensionalfilm or a combination of such film and a non-woven material.
 24. Theprotective underwear of claim 23 wherein said compartment has an area,and wherein said underwear additionally comprises a liquid impermeablelayer disposed between said core and said chassis and encompassing saidarea of said compartment.
 25. The protective underwear of claim 24wherein said liquid impermeable layer is microporous polyfilm, which isvapor permeable.
 26. The protective underwear of claim 24 wherein saidliquid impermeable layer is polyethylene film.
 27. The protectiveunderwear of claim 26 wherein said underwear additionally comprises afluid acquisition layer located between said insert sheet and said core.28. The protective underwear of claim 27 wherein said fluid acquisitionlayer comprises a thru-air-bonded, bicomponent fiber with a fast finishsurfactant.
 29. The protective underwear of claim 26 wherein said fluidacquisition layer comprises an apertured three dimensional film or acombination of such film and a non-woven material.